Prefabricated rapid response accommodation structure
A kit containing all parts necessary for erecting a prefabricated building, or dwelling unit, suitable for normal human occupancy. The building is comprised of prefabricated panels that contain all the necessary cutouts to accommodate prefabricated plumbing and electrical assemblies. The kit also includes all necessary piping and wiring needed to connect such plumbing and electrical assemblies to external sources. The kit will also contain a plurality of adjustable supporting legs for supporting and leveling the building on location.
This invention relates to a kit containing all parts necessary for erecting a prefabricated building, or dwelling unit, suitable for normal human occupancy. The building is comprised of prefabricated panels that contain all the necessary cutouts to accommodate prefabricated plumbing and electrical assemblies. The kit also includes all necessary piping and wiring needed to connect such plumbing and electrical assemblies to external sources. The kit will also contain a plurality of adjustable supporting legs for supporting and leveling the building on location.
BACKGROUND OF THE INVENTIONThere is a continuing and growing need for rapid response prefabricated accommodation structures, such as dwelling units capable of providing living quarters for one or more persons. Such dwelling units are in great need during times of both human and natural disasters, such as wars, hurricanes, floods, earthquakes, etc., for providing shelter for individuals, as well as for entire families. It is speculated that the phenomenon of global warming will increase the incidence of natural disasters, particularly hurricanes. Also, there is growing demand for living space throughout the world with the migration of large sections of the population, in particular the so-called “third world countries” due to wars and poor economies. It is important that such rapid response dwelling units be provided as a kit so that the entire dwelling, along with plumbing and electrical systems can be constructed in a matter of a few hours. Such rapid response dwelling units can also be used during non-disaster times as camps for construction projects in rural locations, as fishing and hunting camps, offices, clinics, temporary school buildings, and the like.
There are numerous prefabricated, both modular and non-modular, buildings known in the art. For example, U.S. Pat. No. 6,766,619 teaches a kit of structural building parts for rapid erection and assembly to form a living space. The building comprises a central prism-like element and corresponding outer elements arranged to form a cuboid structure. Also, U.S. Pat. No. 7,028,440 teaches modular homes comprised of interlocking panels that may form a building assembly comprised of walls and a roof.
Another type of prefabricated building kit is taught in U.S. Pat. No. 5,447,000. The building kit of this '000 patent is a containerized prefabricated building kit comprised of a cuboid frame having eight corners, twelve edges, two side walls, a floor and a roof. Also, U.S. Pat. No. 4,914,879 teaches a prefabricated building system with panels formed from steel studs, the panels provided with supporting runners on their inner and outer edges to secure the panels together.
While various prefabricated buildings are known, some of which have met with commercial success, there is still a need in the art for improved prefabricated building systems that are relatively inexpensive and that are capable of being erected, on site, within a matter of a few hours and being immediately available for human occupancy.
SUMMARY OF THE INVENTIONIn accordance with the present invention there is provided a prefabricated building kit comprised of:
a) building structural members including:
i) a plurality of adjustable legs for supporting said building;
ii) a foundation for said building which foundation is comprised of a rigid beam open structure having outer beams defining the perimeter of said building and at least one cross member beam extending from one side of the open beam structure defining the perimeter to the opposite side;
iii) a plurality of wall panels of suitable size and shape to form exterior and interior walls of said building;
iv) a plurality of floor panels of suitable size and shape for forming said floor of said building;
v) a securing device for securing the bottom of said wall panels forming the outside and interior walls of said building;
vi) a plurality of roof panels of suitable size and shape for forming the roof of said building;
b) plumbing components including: a toilet, a sink, a shower unit, all piping, faucets, shower head and valves necessary to make all plumbing components functional, and the necessary plumbing conduits for bring water into and bringing waste water products out of said building, wherein there is provided cutouts and securing devices at predetermined locations in the interior of said building for all plumbing components and conduits;
c) electrical members including: lighting fixtures, a temperature control unit, a plurality of electrical outlets and switches, an electrical safety disconnect panel for the interior of the building, an electrical panel for the exterior of said building for receiving electrical power from an outside source, and all necessary wiring and circuit breakers to make the electrical members fully operational, wherein a plurality of said prefabricated panels contain cut-outs, securing devices, or both for securing the electrical members at predetermined locations.
In another preferred embodiment of the prefabricated building kit of this invention the electrical fixtures includes both a hot water tank.
In still another preferred embodiment of the present invention the vertical edges of the wall panels of the prefabricated building kit of the present invention include securing means wherein panels can be secured to each other by pressing an edge of one panel against the edge of another panel so that they snap into a locking secured position.
In yet another preferred embodiment of the prefabricated building kit includes one or more furnishing selected from a bed, a clothes closet, a chair and a desk.
The prefabricated building kit of this invention can be one wherein the resulting erected building is of any suitable shape and convenient size for human occupation. It is preferred that the building be a polygon shape, more preferably square or rectangular. The erected prefabricated building will also preferably be one suitable for use as a dwelling for one or more persons displaced because of a natural catastrophe or on assignment at a remote location. The erected building will be stable, rigid and insulated by use of panels containing an insulating core. That is, the building's floor, roof and interior and exterior walls, will all be constructed of a plurality of structural panels of a suitable material wherein at least one exterior panel will contain a door and wherein at least one exterior panel will contain a window. By “of suitable material” means a material that is light weight for economical shipping and ease of construction as well as being capable of providing the required strength and stability to meet governmental regulations at the site where it is erected. Preferred materials for the structural panels are flat panels comprised of a light-weight insulating core sandwiched between fiberglass or metal skins, preferably aluminum or sheet steel skins, more preferably aluminum for weight reasons. The core will preferably be of an insulating foam material, such as those selected from molded expanded polystyrene (MEPS) foam board, extruded expanded polystyrene foam board and polyisocyanurate and polyurethane foam board. More preferred is MPES, which is an extruded polystyrene material. A preferred insulated panel is a panel available from Structall Building Supply which is comprised of a Styrofoam core having sheet metal front and rear faces. Such panels can easily be cut to required shape and size depending on the predetermined dimensions of the building. The one or more windows can be of substantially transparent plastic or of glass, preferably transparent plastic or a shatter resistant safety glass.
The two lateral sides of the structural panels are comprised of any suitable interlocking system wherein one lateral side of a sheet interlocks with an opposing lateral side of another panel. Each structural panel will contain both elements of the interlocking system. That is, one lateral side will have one element integral thereto and the other lateral side will have the complementary interlocking element integral thereto. Such interlocking systems are sometimes referred to as male/female; tongue-and-groove, etc. Preferred interlocking systems are those disclosed in U.S. Pat. Nos. 3,760,548; 4,186,399; 4,769,963; 5,086,599 all of which are incorporated herein by reference. More preferred are the interlocking systems disclosed in U.S. Pat. Nos. 4,769,963 and 5,086,599 which is sometimes referred to as a snap and lock system.
A snap and lock interlocking connecting system is preferred because it allows the structural panels to be jointed together simply by snapping, or sliding, them in place to an adjoining panel and provides a secure substantially leak-proof and air-tight fit. Thus, there is no need for additional securing devices along the length of the panels where they are joined. The more preferred panel for use in the practice of the present invention is a flat panel described in the aforementioned '963 patent wherein one longitudinal or lateral edge of the panel has a first pair of shaped ramp and groove interlock elements, each projecting from one of the thin metal sheets with a shaped wedge of foam core projecting outwardly between the pair of ramp and groove interlock elements. A second opposite longitudinal edge of the panel has a second pair of U-shaped interlock elements each projecting from one of the thin metal sheets with an indentation in the foam core conforming to the wedge of foam core projecting outwardly from an adjacent panel. Adjacent panels are locked together by sliding, or snapping by use of a rocking motion, the U-shaped interlock elements from one panel over the ramp and into the groove of an adjacent panel. The foam core from adjacent panels preferably meet in an edge to edge configuration as the respective interlock elements are snapped together.
Such an interlocking system, which is shown in
The kit will preferably also include all basic furniture such as bed, clothes closet, at least one chair etc. Other furnishing items that can be part of the kit of the present invention include a desk, and end table. Also preferred is that the kit include a temperature control unit. The temperature control unit can be an air conditioner, a heater, or a unit capable of providing both cooling and heating, which units are also referred to as “heating, ventilating, and air conditioning” (HVAC) units.
This invention will be better understood with reference to the figures hereof.
This entire assembly can be secured together by any suitable means. It is preferred that it be secured as shown in
Any suitable building support system can be used in the practice of the present invention as long as it will allow for the height of the building to be adjusted and leveled on site. Preferred adjustable leg supports are those shown in
Claims
1. A prefabricated building kit comprised of:
- a) building structural members including:
- i) a plurality of adjustable legs for supporting said building;
- ii) a foundation for said building which foundation is comprised of a rigid beam open structure having outer beams defining the perimeter of said building and at least one cross member beam extending from one side of the open beam structure defining the perimeter to the opposite side;
- iii) a plurality of wall panels of suitable size and shape to form exterior and interior walls of said building;
- iv) a plurality of floor panels of suitable size and shape for forming said floor of said building;
- v) a securing device for securing the bottom of said wall panels forming the outside and interior walls of said building;
- vi) a plurality of roof panels of suitable size and shape for forming the roof of said building;
- b) plumbing components including: a toilet, a sink, a shower unit, all piping, faucets, shower head and valves necessary to make all plumbing components functional, and the necessary plumbing conduits for bring water into and bringing waste water products out of said building, wherein there is provided cutouts and securing devices at predetermined locations in the interior of said building for all plumbing components and conduits;
- c) electrical members including: lighting fixtures, a temperature control unit, a plurality of electrical outlets and switches, an electrical safety disconnect panel for the interior of the building, an electrical panel for the exterior of said building for receiving electrical power from an outside source, and all necessary wiring and circuit breakers to make the electrical members fully operational, wherein a plurality of said prefabricated panels contain cut-outs, securing devices, or both for securing the electrical members at predetermined locations.
2. The prefabricated building kit of claim 1 wherein the wall panels, the floor panels and the roof panels are comprised of a core of insulating material sandwiched between a sheet metal front face and a sheet metal back face.
3. The prefabricated building kit of claim 2 wherein the insulating core is comprised of a foam material.
4. The prefabricated building kit of claim 3 wherein the foam material is selected from the group consisting of expanded polystyrene, expanded polyisocyanurate and expanded polyurethane.
5. The prefabricated building kit of claim 4 wherein the foam material is an expanded polystyrene and the sheet metal is comprised of aluminum.
6. The prefabricated building kit of claim 1 which includes a hot water tank.
7. The prefabricated building kit of claim 1 wherein the wall panels, the floor panels, and the roof panels have two lateral side and which lateral side have integral thereto a snap and lock type securing system wherein one side of panel can be secured to a side of an adjacent panel.
8. The prefabricated building kit of claim 1 which also includes at least one furnishing selected from a bed, a clothes closet, a chair and a table.
9. The prefabricated building kit of claim 8 which includes all of a bed, a clothes closet, a chair and a table.
Type: Application
Filed: Apr 25, 2007
Publication Date: Oct 30, 2008
Inventor: Mark O. Day (Jackson, LA)
Application Number: 11/789,654
International Classification: E04B 1/343 (20060101); E04B 1/348 (20060101);